WO2021260447A1 - Procédé de réparation d'un endommagement d'un élément composite thermoplastique - Google Patents

Procédé de réparation d'un endommagement d'un élément composite thermoplastique Download PDF

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Publication number
WO2021260447A1
WO2021260447A1 PCT/IB2021/053099 IB2021053099W WO2021260447A1 WO 2021260447 A1 WO2021260447 A1 WO 2021260447A1 IB 2021053099 W IB2021053099 W IB 2021053099W WO 2021260447 A1 WO2021260447 A1 WO 2021260447A1
Authority
WO
WIPO (PCT)
Prior art keywords
socket
patch
thermoplastic composite
cured
composite element
Prior art date
Application number
PCT/IB2021/053099
Other languages
English (en)
Inventor
Adam Dworak
Aleksander BANAS
Janusz MADRY
Jaroslaw SIENICKI
Marcin GLODZIK
Original Assignee
Polskie Zaklady Lotnicze Spolka Z Ograniczona Odpowiedzialnoscia
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Polskie Zaklady Lotnicze Spolka Z Ograniczona Odpowiedzialnoscia filed Critical Polskie Zaklady Lotnicze Spolka Z Ograniczona Odpowiedzialnoscia
Priority to EP21720573.1A priority Critical patent/EP4168244A1/fr
Priority to US18/001,989 priority patent/US20230347603A1/en
Publication of WO2021260447A1 publication Critical patent/WO2021260447A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0067—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other
    • B29C37/0075—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other using release sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24—Apparatus or accessories not otherwise provided for
    • B29C73/26—Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • B29C2073/268—Apparatus or accessories not otherwise provided for for mechanical pretreatment for drilling holes in the area to be repaired
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
    • B29C73/12—Apparatus therefor, e.g. for applying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24—Apparatus or accessories not otherwise provided for
    • B29C73/26—Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts

Definitions

  • the invention relates to a method of repairing damage to a thermoplastic composite element, in particular an aircraft element damaged during operation.
  • thermoplastic composites One of the problems associated with operation of elements made of thermoplastic composites is the occurrence of damage caused by a hit of an external object or cracks resulting from the intense structural movement of the composite structure. Repair of damaged structures made of welding, mechanical or energy-assisted. In these cases, a repair consists in welding together fragments of damaged thermoplastic composite element.
  • thermoplastic composites In the currently used methods of welding together elements made of thermoplastic composites, and thus also repairing damaged elements made of these composites, the plasticization effect of a polymer matrix of the thermoplastic composite when subjected to high temperatures is used; however, this requires heating the edges of the damaged element to be heated to temperatures close to the melting point of the matrix polymer.
  • polymers with a high melting point such as polyetheretherketone (PEEK)
  • PEEK polyetheretherketone
  • the aim of the present invention was to provide a method of repairing damage to a thermoplastic composite element devoid of the above-discussed disadvantages of known solutions, and in particular a method allowing to repair damaged elements of a thermoplastic structure with variable geometry without the need to adjust the tooling used each time, as well as to eliminate the need to use special tooling for molding thermoplastic composites and the need to supply large amounts of heat to the area to be repaired, even in case of thermoplastic composites with a matrix of high melting polymers, such as e.g. PEEK.
  • the subject of the invention is a method of repairing damage to a thermoplastic composite element, in particular an aircraft element, wherein a socket is milled at the site of damage to the thermoplastic composite element.
  • a patch of thermosetting material comprising a reinforcement phase of fabric layers and a matrix of thermosetting resin is formed in this socket, said patch having a shape and size corresponding to the socket geometry.
  • the patch is cured and finally the cured patch is glued into the socket by means of an adhesive.
  • the socket is milled layer-wise to form a stepped structure on the damaged surface of the thermoplastic composite element.
  • the following are placed sequentially:
  • repair pack is attached to the surface of the thermoplastic composite element to be repaired, air is pumped out of the repair pack.
  • the patch of thermosetting material is cured using a heating blanket provided with an external portable power supply and control device.
  • the adhesive is a thermosetting adhesive, but it is also possible to use other adhesives applied as a thin layer and curable as a result of a chemical reaction, e.g. between the components of a two-component adhesive.
  • the thermosetting adhesive as an adhesive, preferably in the step of gluing the cured patch into the socket, the adhesive layer is applied to the contact surface of the socket and the cured patch, next the cured patch is pressed into the socket, and then on the cured patch placed in the socket the following elements are placed sequentially: the perforated separating foil, the absorbing fabric, the separating film, the heating blanket, the breathable fabric and the vacuum foil, and afterwards the entire vacuum package thus formed is sealed to the surface of the thermoplastic composite element to be repaired by means of the sealing tape, preferably a butyl tape, air is pumped out of the package and the adhesive layer is cured using a heating blanket provided with the external portable power supply and control device.
  • the sealing tape preferably a butyl tape
  • the matrix is polyetheretherketone (PEEK) and the reinforcing phase is carbon fiber.
  • PEEK polyetheretherketone
  • carbon fiber fabric layers are used as the reinforcing phase of the thermosetting material.
  • an epoxy resin is used as the matrix of the thermosetting material.
  • the method according to the invention allows for the repair of damages to a thermoplastic composite element that can be implemented in hangar conditions, without the need to use complicated and expensive equipment, without the need to supply large amounts of heat to the repaired area, and at the same time maintaining a high quality of the repaired damage, guaranteeing its sufficient strength mechanical.
  • fig. 1 shows the step of curing a patch of thermosetting material in a socket milled in a damaged thermoplastic composite element
  • fig. 2 shows the step of gluing the cured patch of the thermoset composite into the socket milled in the damaged thermoplastic composite element.
  • the damaged element to be repaired is made of a thermoplastic composite, in which the matrix is polyetheretherketone (PEEK) and the reinforcing phase is carbon fiber.
  • PEEK polyetheretherketone
  • a socket 14 is milled at the site of the damage to the thermoplastic composite element 10, the milling being performed layer- wise to form a stepped structure on the surface of the damage to the thermoplastic composite element 10.
  • the original irregular shape of the identified damage e.g. a crack, a cavity
  • a milled socket with the so-called stepped gradation formed by removing the thermoplastic composite layer-wise from the damaged area, starting from the deepest point of the damage to the surface of the repaired element, the area of each successively removed layer being larger than the previous one.
  • a repair patch is formed in the socket 14, said patch being made of a thermosetting material containing a reinforcement phase of fabric layers and a matrix of a thermosetting resin.
  • the reinforcing phase of the thermosetting material is made of carbon fiber fabric layers 11, and the matrix is epoxy resin.
  • the socket 14 is lined with a separating layer 1, which in the exemplary embodiment is Tooltec ® A007 foil from Airtech [polyethylene terephthalate (PTFE) foil tape reinforced with glass fiber and provided with a layer of silicone adhesive].
  • Such prepared patch is covered successively with: a perforated separating foil 2 (which in the exemplary embodiment is RF-2500-RED-30-1370- NP-NP-FNS foil), an absorbing fabric 3 [which in the exemplary embodiment is Econostitch ® delaminating polyamide fabric from Airtech], a separating foil 4 [which in the exemplary embodiment is RF-2500-RED-30-1370-PIN-P3-FNS foil], a heating blanket 5 [which in the exemplary embodiment is a heating blanket with a Leslie portable power supply and control device], a breathable fabric 6 [which in the exemplary embodiment is the medium weight polyester mat Econoweaver ® 44 from Airtech] and a vacuum foil 7 [which in the exemplary embodiment is Wrightlon ® 5400 polyamide film from Airtech]
  • the entire repair package thus formed is sealed to the surface of the thermoplastic composite component 10 being repaired by means of a sealing tape 8, which in the exemplary embodiment is a butyl tape.
  • the patch curing takes place in the socket 14 lined with a separating layer 1, so that the cured patch 13 has a shape that accurately reflects the geometry of the socket 14 milled in the repaired element and completely fills the socket.
  • the cured patch 13 thus prepared is glued into the socket 14 by means of an adhesive 9, which in the exemplary embodiment is a thermosetting adhesive, such as LOCTITE EA 9323 two-component epoxy adhesive paste from Henkel.
  • thermosetting adhesive is applied to the contact surface of the socket 14 and the cured patch 13, and then the cured patch 13 is pressed into the socket 14.
  • the following elements are placed sequentially on the cured patch (13) placed in the socket (14): the perforated separating film 2, the absorbing fabric 3, the separating foil 4, the heating blanket 5, the breathable fabric 6 and the vacuum foil 7.
  • the entire vacuum packet thus formed is sealed to the surface of the repaired thermoplastic composite element 10 by means of a sealing tape 8, which in the exemplary embodiment is a butyl tape. Air is pumped out of the packet and the thermosetting adhesive layer is cured using the heating blanket 5 provided with the external portable power supply and control device 12.
  • the permanently glued cured patch 13 prevents further damage propagation.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)

Abstract

L'invention se rapporte à un procédé de réparation d'un endommagement d'un élément composite thermoplastique, en particulier d'un composant d'aéronef, une alvéole (14) étant fraisée au niveau du site d'endommagement de l'élément composite thermoplastique (10). Ensuite, dans ladite alvéole, une pièce est formée à partir d'un matériau thermodurcissable contenant une phase de renforcement de couches de tissu et une matrice de résine thermodurcissable, ladite pièce ayant une forme et une taille correspondant à la géométrie de l'alvéole (14). À l'étape suivante, la pièce est durcie, et enfin, la pièce durcie (13) est collée dans l'alvéole (14) au moyen d'un adhésif (9).
PCT/IB2021/053099 2020-06-22 2021-04-15 Procédé de réparation d'un endommagement d'un élément composite thermoplastique WO2021260447A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP21720573.1A EP4168244A1 (fr) 2020-06-22 2021-04-15 Procédé de réparation d'un endommagement d'un élément composite thermoplastique
US18/001,989 US20230347603A1 (en) 2020-06-22 2021-04-15 Method of repairing damage to a thermoplastic composite element

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PL434397A PL434397A1 (pl) 2020-06-22 2020-06-22 Sposób naprawy uszkodzeń elementu z kompozytu termoplastycznego
PLPL434397 2020-06-22

Publications (1)

Publication Number Publication Date
WO2021260447A1 true WO2021260447A1 (fr) 2021-12-30

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2021/053099 WO2021260447A1 (fr) 2020-06-22 2021-04-15 Procédé de réparation d'un endommagement d'un élément composite thermoplastique

Country Status (3)

Country Link
US (1) US20230347603A1 (fr)
PL (1) PL434397A1 (fr)
WO (1) WO2021260447A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115042458A (zh) * 2022-06-22 2022-09-13 沈阳飞机工业（集团）有限公司 一种可用于飞机盒段结构复合材料构件的胶接修补工艺
CN115091794A (zh) * 2022-07-28 2022-09-23 大连理工大学 一种热塑性复合材料损伤修复方法
GB2617616A (en) * 2022-04-14 2023-10-18 Airbus Operations Ltd Method of repairing a composite beam

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9545782B2 (en) * 2014-05-13 2017-01-17 The Boeing Company Method and apparatus for repairing composite materials
WO2017081456A1 (fr) * 2015-11-11 2017-05-18 Short Brothers Plc Procédés et patches pour la réparation de stratifiés composites
US20190310081A1 (en) * 2016-11-15 2019-10-10 Bayab Industries Method and system for inspecting ply-by-ply machining of multilayer materials

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9545782B2 (en) * 2014-05-13 2017-01-17 The Boeing Company Method and apparatus for repairing composite materials
WO2017081456A1 (fr) * 2015-11-11 2017-05-18 Short Brothers Plc Procédés et patches pour la réparation de stratifiés composites
US20190310081A1 (en) * 2016-11-15 2019-10-10 Bayab Industries Method and system for inspecting ply-by-ply machining of multilayer materials

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2617616A (en) * 2022-04-14 2023-10-18 Airbus Operations Ltd Method of repairing a composite beam
CN115042458A (zh) * 2022-06-22 2022-09-13 沈阳飞机工业（集团）有限公司 一种可用于飞机盒段结构复合材料构件的胶接修补工艺
CN115091794A (zh) * 2022-07-28 2022-09-23 大连理工大学 一种热塑性复合材料损伤修复方法

Also Published As

Publication number Publication date
PL434397A1 (pl) 2021-12-27
US20230347603A1 (en) 2023-11-02

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